Article of footwear including a bladder element having a cushioning component with a single central opening and a cushioning component with multiple connecting features and method of manufacturing

ABSTRACT

An article of footwear is disclosed that comprises a sole structure having a bladder element that includes multiple cushioning components. Each cushioning component includes an enclosed fluid-filled cavity. The cushioning components may include a first cushioning component and a second cushioning component. The first cushioning component has a single central opening extending completely therethrough, and a continuous fluid-filled cavity surrounding the central opening. The second cushioning component has multiple connecting features positioned inward of an outer periphery of the second cushioning component. The connecting features connect a first side of the second cushioning component to a second side of the second cushioning component opposite the first side. A method of manufacturing an article of footwear with such cushioning components is disclosed.

CROSS-REFERENCE TO RELATED APPLICATIONS

This is a divisional application of and claims the benefit of priorityto U.S. application Ser. No. 14/931,287, filed on Nov. 3, 2015, which ishereby incorporated by reference in its entirety.

TECHNICAL FIELD

The present teachings generally include an article of footwear with asole structure having a bladder element, and a method of manufacturing asole structure of an article of footwear.

BACKGROUND

Footwear typically includes a sole configured to be located under awearer's foot to space the foot away from the ground or floor surface.Athletic footwear in particular sometimes utilizes polyurethane foam orother resilient materials in the sole to provide cushioning.Fluid-filled bladders are sometimes included in the sole to providedesired impact force absorption, motion control, and resiliency.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a schematic illustration in side view of an article offootwear having a sole structure and showing a bladder element withhidden lines.

FIG. 2 is a schematic illustration in plan view of the bladder elementof FIG. 1 showing a perimeter of the sole structure in phantom.

FIG. 3 is a schematic cross-sectional illustration of a first cushioningcomponent the bladder element of FIG. 2 taken at lines 3-3 in FIG. 2.

FIG. 4 is a schematic illustration in fragmentary plan view of analternative configuration of a cushioning component for the bladderelement of FIG. 2.

FIG. 5 is a schematic cross-sectional illustration of the cushioningcomponent of FIG. 4 taken at lines 5-5 in FIG. 4.

FIG. 6 is a schematic cross-sectional illustration of anotheralternative configuration of a cushioning component of the bladderelement of FIG. 2.

FIG. 7 is a schematic cross-sectional illustration of a secondcushioning component of the bladder element of FIG. 2 taken at lines 7-7in FIG. 2 showing tubular pillars.

FIG. 8 is a schematic cross-sectional illustration of the bladderelement of FIG. 2 taken at the same lines as FIG. 7 prior to punchingholes in the bladder element at the centers of the tubular pillars.

FIG. 9 is a schematic cross-sectional illustration of the bladderelement of FIG. 2 taken at lines 9-9 in FIG. 2.

FIG. 10 is a schematic cross-sectional illustration of the solestructure of FIG. 1 taken at lines 10-10 in FIG. 1.

FIG. 11 is a schematic illustration in plan view of a bladder elementfor the sole structure of FIG. 1 in accordance with an alternativeaspect of the present teachings.

FIG. 12 is a schematic cross-sectional illustration of the bladderelement of FIG. 11 taken at lines 12-12 in FIG. 11.

FIG. 13 is a schematic cross-sectional illustration of a mold assemblyfor thermoforming the bladder element of FIG. 1 from polymer sheets atthe same cross-section as FIG. 3.

DESCRIPTION

An article of footwear is disclosed that comprises a sole structurehaving a bladder element that includes multiple cushioning components.Each cushioning component includes an enclosed fluid-filled cavity. Thecushioning components include a first cushioning component and a secondcushioning component. The first cushioning component has a singlecentral opening extending completely therethrough, and a continuousfluid-filled cavity surrounding the central opening. The secondcushioning component has multiple connecting features positioned inwardof an outer periphery of the second cushioning component. The connectingfeatures connect a first side of the second cushioning component to asecond side of the second cushioning component opposite the first side.

In an embodiment, the cushioning components are spaced apart from oneanother so that an outer surface of each of the cushioning components issubstantially decoupled from an outer surface of an adjacent one of thecushioning components.

In an embodiment, the first cushioning component is a regular ring torusor an irregular ring torus.

In an embodiment, the connecting features are tubular pillars. At leastone of the tubular pillars may comprise an opening extending completelythrough said at least one of the tubular pillars. The tubular pillarwith the opening extending completely therethrough may be hollow.

In an embodiment, the connecting features are tethers positioned withinthe fluid-filled cavity of the second cushioning component.

In an embodiment, the cushioning components comprise a third cushioningcomponent and a fourth cushioning component. The third cushioningcomponent includes a single central opening extending completelytherethrough, and a continuous fluid-filled cavity surrounding thecentral opening of the third cushioning component. The fourth cushioningcomponent includes multiple connecting features positioned inward of anouter periphery of the fourth cushioning component and connecting afirst side of the fourth cushioning component to a second side of thefourth cushioning component opposite the first side of the fourthcushioning component. The first cushioning component is positionedbetween a medial extremity of the sole structure and the thirdcushioning component. The third cushioning component is positionedbetween a lateral extremity of the sole structure and the firstcushioning component. The second cushioning component is positionedbetween the medial extremity of the sole structure and the fourthcushioning component. The fourth cushioning component is positionedbetween the lateral extremity of the sole structure and the secondcushioning component.

In an embodiment, the cushioning components further comprise a fifthcushioning component that has a single central opening extendingcompletely therethrough, and a continuous fluid-filled cavitysurrounding the central opening of the fifth cushioning component. Thefifth cushioning component is rearward of the third cushioning componentand positioned in a midfoot portion of the sole structure.

In an embodiment, the first cushioning component and the secondcushioning component are both positioned in a forefoot portion of thesole structure, and the second cushioning component is positionedforward of the first cushioning component.

In an embodiment, the second cushioning component is in a heel portionof the article of footwear and includes tubular portions extending alonga periphery of the sole structure in the heel portion.

In an embodiment, the cushioning components comprise a tubularcushioning component extending lengthwise along a medial extremity ofthe sole structure in a midfoot portion of the sole structure.

In an embodiment, the bladder element includes channels connectingadjacent ones of the cushioning components and establishing fluidcommunication between said adjacent ones of the cushioning components.At least one of the channels may be sealed so that the adjacent ones ofthe cushioning components connected by the sealed channel are isolatedfrom fluid communication with one another by the sealed channel. Theadjacent ones of the cushioning components connected by the sealedchannel may have different inflation pressures.

In an embodiment, a gap is provided between adjacent ones of thecushioning components and extends from a medial extremity to a lateralextremity of the sole structure.

Substantially decoupling the cushioning components allows at least someof the outer surfaces of the cushioning components to be surrounded byor encased in foam in some embodiments. Gaps between the lengths of thetubes may be filled with the foam, or may be free from foam or otherstructure. The foam-filled or empty gaps allow for increased fore-aftflexibility of the sole structure in comparison to a bladder element inwhich outer surfaces of adjacent cushioning components are notsubstantially decoupled.

An article of footwear is disclosed that comprises a sole structurehaving a bladder element that includes a cushioning component. Thecushioning component includes a fluid-filled cavity and multiple tubularpillars that are positioned inward of an outer periphery of thecushioning component. The tubular pillars connect a first side of thecushioning component to a second side of the cushioning componentopposite the first side such that the fluid-filled cavity surrounds thetubular pillars. At least one of the tubular pillars comprises anopening extending completely therethrough.

In an embodiment, the article of footwear further comprises anadditional cushioning component. The additional cushioning componentincludes a single central opening extending completely therethrough, acontinuous fluid-filled cavity surrounding the central opening. Thebladder element further comprises a channel connecting the cushioningcomponent to the additional cushioning component.

In an embodiment, the cushioning component is in one of a forefootportion of the sole structure and a heel portion of the sole structure.For example, the cushioning component may be in the heel portion of thesole structure and may include tubular portions extending along an edgeof the sole structure in the heel portion.

In an embodiment, the channel is sealed such that the fluid-filledcavity of the cushioning component is isolated from fluid communicationwith the fluid-filled cavity of the additional cushioning component bythe sealed channel.

A method of manufacturing a sole structure of an article of footwearcomprises forming a bladder element having multiple cushioningcomponents. Each cushioning component includes a fluid-filled cavity.The cushioning components comprise a first cushioning component that hasa single central opening extending completely therethrough, and has acontinuous fluid-filled cavity surrounding the central opening. Thecushioning components further comprise a second cushioning componentthat has multiple connecting features positioned inward of an outerperiphery of the second cushioning component and that connect a firstside of the second cushioning component to a second side of the secondcushioning component opposite the first side. The second cushioningcomponent is substantially decoupled from the first cushioningcomponent.

In an embodiment of the method, the multiple connecting features arehollow tubes, and forming the bladder element includes positioningpolymeric sheets in the mold assembly and thermoforming the polymericsheets in the mold assembly to include tubular pillars. The methodfurther comprises punching holes in the polymeric sheets at the tubularpillars so that the tubular pillars are hollow.

In an embodiment of the method, forming the bladder element comprisesforming channels connecting adjacent ones of the cushioning componentsto establish fluid communication between the adjacent ones of thecushioning components, and forming an inflation port disposed at aperiphery of the bladder element and in fluid communication with theadjacent ones of the cushioning components via the channels. The methodfurther comprises inflating the bladder element through the inflationport to a first inflation pressure, closing one of the channels to forma sealed first portion of the bladder element, and inflating a remainingunsealed portion of the bladder element through the inflation port to asecond inflation pressure, thereby establishing different inflationpressures in different ones of the cushioning components separated fromone another by the closed channel.

In an embodiment, the method further comprises at least partiallycovering an outer surface of at least one of the cushioning componentswith foam.

The above features and advantages and other features and advantages ofthe present teachings are readily apparent from the following detaileddescription of the modes for carrying out the present teachings whentaken in connection with the accompanying drawings.

“A,” “an,” “the,” “at least one,” and “one or more” are usedinterchangeably to indicate that at least one of the items is present. Aplurality of such items may be present unless the context clearlyindicates otherwise. All numerical values of parameters (e.g., ofquantities or conditions) in this specification, unless otherwiseindicated expressly or clearly in view of the context, including theappended claims, are to be understood as being modified in all instancesby the term “about” whether or not “about” actually appears before thenumerical value. “About” indicates that the stated numerical valueallows some slight imprecision (with some approach to exactness in thevalue; approximately or reasonably close to the value; nearly). If theimprecision provided by “about” is not otherwise understood in the artwith this ordinary meaning, then “about” as used herein indicates atleast variations that may arise from ordinary methods of measuring andusing such parameters. In addition, a disclosure of a range is to beunderstood as specifically disclosing all values and further dividedranges within the range. All references referred to are incorporatedherein in their entirety.

The terms “comprising,” “including,” and “having” are inclusive andtherefore specify the presence of stated features, steps, operations,elements, or components, but do not preclude the presence or addition ofone or more other features, steps, operations, elements, or components.Orders of steps, processes, and operations may be altered when possible,and additional or alternative steps may be employed. As used in thisspecification, the term “or” includes any one and all combinations ofthe associated listed items. The term “any of” is understood to includeany possible combination of referenced items, including “any one of” thereferenced items. The term “any of” is understood to include anypossible combination of referenced claims of the appended claims,including “any one of” the referenced claims.

Those having ordinary skill in the art will recognize that terms such as“above,” “below,” “upward,” “downward,” “top,” “bottom,” etc., are useddescriptively relative to the figures, and do not represent limitationson the scope of the invention, as defined by the claims.

Referring to the drawings wherein like reference numbers refer to likecomponents throughout the several views, FIG. 1 shows an article offootwear 10 in a lateral side view. As shown, the article of footwear 10is an athletic shoe. In other embodiments, the article of footwear 10could be for another category of footwear, such as a dress shoe, a workshoe, a sandal, a slipper, or a boot.

The article of footwear 10 includes an upper 12 configured with a cavitythat receives a foot 14 of a wearer. The upper 12 can be a variety offlexible materials such as textiles, and fabrics, and may includeplastic support components. The upper 12 may be multiple pieces sewn,knitted, or bonded to one another. The upper 12 may include a lacingsystem or may be a slip-on sock. The upper 12 may further includesupport elements, such as a heel counter. The upper 12 is shown worn onthe foot 14, which is shown in phantom.

The article of footwear 10 includes a sole structure 16 operativelysecured to the upper 12 and providing cushioning between the foot 14 andthe ground G. The article of footwear 10 and the sole structure 16 havea forefoot portion 18, a midfoot portion 20, and a heel portion 22. Theforefoot portion 18 generally includes portions of the sole structure 16corresponding with the toes and the joints connecting the metatarsalswith the phalanges of the foot 14. The midfoot portion 20 generallycorresponds with an arch area of the foot 14, and extends from theforefoot portion 18 to a heel portion 22. The heel portion 22 generallycorresponds with rear portions of the foot 14, including the calcaneusbone, with the foot 14 corresponding in size to the article of footwear10. The heel portion 22 is defined as approximately the rear third ofthe sole structure 16. The midfoot portion 20 is defined as the middlethird of the sole structure 16. The forefoot portion 18 is defined asthe front third of the sole structure 16. A perimeter P of the solestructure 16 surrounds the forefoot portion 18, the midfoot portion 20,and the heel portion 22. The article of footwear 10 shown is for a leftfoot. A pair of footwear includes the article of footwear 10, and anarticle of footwear for a right foot that is a mirror image of thearticle of footwear 10.

The sole structure 16 has a lateral side 24 best shown in FIG. 1, and amedial side 26 indicated in FIG. 2. The lateral side 24 includes allportions of the sole structure 16 on a side of a longitudinal midline Lclosest to a lateral side of the foot 14. The medial side 26 includesall portions of the sole structure 16 on a side of the longitudinalmidline L closest to a medial side of the foot 14. The lateral side 24of the sole structure 16 is a side that corresponds with the side of thefoot 14 that is generally further from the other foot of the wearer(i.e., the side closer to the fifth toe of the wearer). The fifth toe iscommonly referred to as the little toe. The medial side 26 of the solestructure 16 is the side that corresponds with an inside area of thefoot 14 and is generally closer to the other foot of the wearer (i.e.,the side closer to the hallux of the foot of the wearer). The hallux iscommonly referred to as the big toe.

The sole structure 16 includes a fluid-filled bladder element 30 shownand discussed in further detail with respect to FIG. 2. In FIG. 1, thesole structure 16 also includes foam 32 that covers at least some of theouter surfaces of the bladder element 30. For example, the foam 32 maybe but is not limited to ethylene vinyl acetate (EVA) foam orpolyurethane foam. In addition to foam 32, the sole structure 16 mayinclude an outsole or discreet outsole elements (not shown) between thefoam 32 and the ground G or directly attached to the bladder element 30between the bladder element 30 and the ground G. For example, theoutsole or outsole elements may be rubber or another relatively durablematerial for providing traction and grip. Alternatively, the foam 32 mayserve as a unitary midsole and outsole. The sole structure 16 may alsoinclude various support elements, such as one or more plates that mayalso be encased in the foam 32. Still further, no foam may be used. Forexample, the bladder element 30 could instead be directly attached tothe upper 12, or a layer could be attached to the upper 12 and thebladder element 30 could be attached to a ground-facing side of thelayer. For example, the layer could be a midsole layer or a layer withdifferential stiffness. Outsole elements may be attached to or madeintegral with the bladder element 30 in such an embodiment.

The bladder element 30 is a polymeric material capable of retaining apressurized fluid. For example, the bladder element 30 may comprise athermoplastic polyurethane material (TPU). Optionally the TPU may berecyclable and regrindable, and may be made from recycled TPU, allowingthe material of the bladder element 30 to be recycled and reused.

The bladder element 30 may be blow molded or alternatively may bethermoformed from upper and lower sheets. The sheets may havealternating layers of TPU and a gas barrier material. In any embodiment,the bladder element 30 is configured to retain fluid within thefluid-filled chambers. As used herein, a “fluid” includes a gas,including air, an inert gas such as nitrogen, or another gas.Accordingly, “fluid-filled” includes “gas-filled”. The various materialsused for the bladder element 30 may be substantially transparent or mayhave a tinted color. For example, the bladder element 30 can be formedfrom any of various polymeric materials that can retain a fluid at apredetermined pressure, including a fluid that is a gas, such as air,nitrogen, or another gas. For example, the bladder element 30 can be aTPU material, a urethane, polyurethane, polyester, polyesterpolyurethane, and/or polyether polyurethane.

Moreover, in one embodiment, the bladder element 30 can be formed of oneor more sheets having layers of different materials. The sheets may belaminate membranes formed from thin films having one or more firstlayers that comprise thermoplastic polyurethane layers and thatalternate with one or more second layers, also referred to herein asbarrier layers, gas barrier polymers, or gas barrier layers. The secondlayers may comprise a copolymer of ethylene and vinyl alcohol (EVOH)that is impermeable to the pressurized fluid contained therein asdisclosed in U.S. Pat. No. 6,082,025 to Bonk et al., which isincorporated by reference in its entirety. The first layer may bearranged to form an outer surface of the polymeric sheet. That is, theoutermost first layer may be the outer surface of the bladder element30. The bladder element 30 may also be formed from a material thatincludes alternating layers of thermoplastic polyurethane andethylene-vinyl alcohol copolymer, as disclosed in U.S. Pat. Nos.5,713,141 and 5,952,065 to Mitchell et al. which are incorporated byreference in their entireties. Alternatively, the layers may includeethylene-vinyl alcohol copolymer, thermoplastic polyurethane, and aregrind material of the ethylene-vinyl alcohol copolymer andthermoplastic polyurethane. The bladder element 30 may also be aflexible microlayer membrane that includes alternating layers of a gasbarrier polymer material such as second layers and an elastomericmaterial such as first layers, as disclosed in U.S. Pat. Nos. 6,082,025and 6,127,026 to Bonk et al. which are incorporated by reference intheir entireties. With such alternating layers, for example, the bladderelement 30 or any of the additional bladder elements discussed hereinmay have a gas transmission rate for nitrogen of less than 10 cubiccentimeters per square meter per atmosphere per day, or of less than 1cubic centimeter per square meter per atmosphere per day. Additionalsuitable materials for the bladder element 30 are disclosed in U.S. Pat.Nos. 4,183,156 and 4,219,945 to Rudy which are incorporated by referencein their entireties. Further suitable materials for the bladder element30 include thermoplastic films containing a crystalline material, asdisclosed in U.S. Pat. Nos. 4,936,029 and 5,042,176 to Rudy, andpolyurethane including a polyester polyol, as disclosed in U.S. Pat.Nos. 6,013,340, 6,203,868, and 6,321,465 to Bonk et al. which areincorporated by reference in their entireties. In selecting materialsfor the bladder element 30, engineering properties such as tensilestrength, stretch properties, fatigue characteristics, dynamic modulus,and loss tangent can be considered. When the bladder element 30 isformed from sheets, the thicknesses of the sheets used to form thebladder element 30 can be selected to provide these characteristics.

The bladder element 30 includes multiple cushioning components. Morespecifically, the bladder element 30 includes cushioning components 34A,34B, 34C, 35A, 35B, 35C, and 36. Each cushioning component 34A, 34B,34C, 35A, 35B, 35C, and 36 includes an enclosed fluid-filled cavity.Cushioning component 34A includes a fluid-filled cavity 38A. Cushioningcomponent 34B includes a fluid-filled cavity 38B. Cushioning component34C includes a fluid-filled cavity 38C. Cushioning component 35Aincludes a fluid-filled cavity 38D. Cushioning component 35B includes afluid-filled cavity 38E. Cushioning component 35C includes afluid-filled cavity 38F. Cushioning component 36 includes a fluid-filledcavity 38G.

The cushioning components 34A, 34B, and 34C each have a single centralopening that extends completely therethrough. As used herein, a “centralopening” need not be positioned at a true center of the cushioningcomponent. More specifically, if the cushioning component is a regulartorus, the cushioning component will have a center axis and the centralopening will be centered at the center axis. If the cushioning componentis an irregular torus, the central opening does not have a center axis,and although it is bounded by the material of the cushioning component,the central opening is therefore not centered within the cushioningcomponent.

Cushioning component 34A has a single central opening 40A that extendscompletely therethrough. The fluid-filled cavity 38A is a continuousfluid-filled cavity that completely surrounds the central opening 40A.Cushioning component 34B has a single central opening 40B that extendscompletely therethrough. The fluid-filled cavity 38B is a continuousfluid-filled cavity that completely surrounds the central opening 40B.Cushioning component 34C has a single central opening 40C that extendscompletely therethrough. The fluid-filled cavity 38C is a continuousfluid-filled cavity that completely surrounds the central opening 40C.

Each of the cushioning components 34A, 34B, 34C is a ring torus. Asshown, each of the cushioning components 34A, 34B, 34C is an irregularring torus. Alternatively, one or more of the cushioning components 34A,34B, 34C could be configured as a regular ring torus. As used herein, an“irregular ring torus” is a surface or solid formed by rotating a closedshape, such as but not limited to a circle, an oval, a square, or arectangle, around a line that lies in the same plane as the closed shapebut does not intersect the closed shape (e.g., like a ring-shapeddoughnut), wherein the closed shape varies as it is rotated about theline, the distance from the line varies as the closed shape is rotatedabout the line, or both vary. A “regular ring torus” is a surface orsolid formed by rotating a closed shape, such as but not limited to acircle, an oval, a square, or a rectangle, around a line that lies inthe same plane as the closed shape but does not intersect the closedshape (e.g., like a ring-shaped doughnut), wherein neither the closedshape nor the distance from the line varies as the closed shape isrotated about the line.

FIG. 4 is an example of a cushioning component 34AA that is a regularring torus and that could be used in place of cushioning component 34A.The cushioning component 34AA is a closed circle in cross-section (andwith a flange 79 as discussed herein) that is rotated around the line L3illustrated in FIG. 5 to form the ring torus of FIG. 4. The cushioningcomponent 34AA is thus equidistant from the line L3 at any cross-sectionof the cushioning component 34AA through a plane that includes the lineL3, and the line L3 is thus a center axis of the cushioning component34AA. Alternatively, if the cushioning component 34AA is blow molded, itwill not include the flange 79.

FIG. 6 is another example of a cushioning component 34BB that can beused in place of the cushioning component 34 and the cushioningcomponent 34AA. The cushioning component 34BB is substantially a closedrectangle in cross-section and, like cushioning component 34A, isrotated around the line L3 and is a regular ring torus. The cushioningcomponents 34A, 34B, 34C are each an irregular ring torus because noneof these are configured to be equidistant from a center axis such asline L3. Additionally, each is an irregular ring torus because theclosed shape of the component in cross-section varies and is not uniformat all cross-sections taken in a plane that includes an axis through thecentral opening. For example, it is apparent in FIG. 2 that across-section of the cushioning component 34C would be wider at corners42A, 42B than along relatively straight portions 44A, 44B.

By configuring each cushioning component 34A, 34B, 34C as a regular orirregular ring torus, a relatively large cushioning area is providedwhile the overall height of the cushioning component is relatively smallin comparison to its width. For example, if the cushioning component 34Adid not have the center opening 40A, it would tend to inflate in a ballshape, causing it to be much higher at its center. Additionally, thecentral opening 40A allows deflection of the cushioning component 34Adownward and inward toward the central opening 40A.

The cushioning components 35A, 35B, and 35C of FIG. 2 are configureddifferently than the cushioning components 34A, 34B, and 34C. Morespecifically, each of the cushioning components 35A, 35B, and 35C hasmultiple connecting features 44. As shown in FIG. 7 with respect tocushioning component 35A, the connecting features 44 are positionedinward of an outer periphery 45A of the cushioning component 35A. Theconnecting features 44 connect a first side 50A of the cushioningcomponent 35A to a second side 52A of the cushioning component 35Aopposite the first side 50A. In the embodiment of FIG. 2, the connectingfeatures 44 are tubular pillars and may be referred to as such. Thematerial of the bladder element 30 forms the tubular pillars 44. Thetubular pillars 44 are hollow, as each includes an opening 46 thatextends completely through the tubular pillar 44. The tubular pillars 44could be originally formed with the opening 46 extending completelytherethrough as hollow pillars during forming of the bladder element 30,such as by blow molding or thermoforming the bladder element 30.Alternatively, the material of the bladder element 30 could initiallyextend across the tubular pillar 44 at a center area 48 as shown in FIG.8. Holes 51 shown in FIG. 7 are then punched through the bladder element30 at the center of each tubular pillar 44 so that the tubular pillars44 are hollow and the opening 46 extends completely therethrough. Forexample, the bladder element 30 could be formed from a first polymericsheet 70 and a second polymeric sheet 72 positioned between first andsecond mold halves 74, 76 of a mold assembly 78. The sheets 70, 72 arevacuum-formed and thermoformed to mold surfaces 74A, 76A shown in FIG.13, and compression formed to one another at a peripheral flange 79indicated in FIG. 3 to form all of the cushioning components 34A, 34B,34C, 35A, 35B, and 36. In such an embodiment, the sheets 70, 72 wouldinitially be bonded to one another at the center area 48 at each of thetubular pillars 44 as shown in FIG. 8. Similarly, the sheets 70, 72would initially be bonded to one another in the area of the centralopenings 40A, 40B, 40C, and the central openings 40A, 40B, 40C could bepunched out.

The tubular pillars 44 of the cushioning components 35B and 35C areconfigured in a like manner as described with respect to the tubularpillars 44 of the cushioning component 35A. The cushioning components35B and 35C are configured similarly to cushioning component 35A, withthe tubular pillars 44 positioned inward of an outer periphery 45B, 45Cof the cushioning components 35B, 35C, respectively, and connecting afirst side to a second side of each of the cushioning components 35B,35C, as indicated with respect to the cushioning component 35A.

Referring to FIG. 2, the cushioning component 35C is in the heel portion22 of the sole structure 16 and the article of footwear 10. Thecushioning component 35C includes extended tubular portions 60A, 60Bthat extend along a periphery P of the sole structure 16 in the heelportion 22. More specifically, the tubular portion 60A extends along theperiphery P at a lateral extremity 60 of the sole structure 16, and thetubular portion 60B extends along the periphery P at a medial extremity62 of the sole structure 16. The tubular portions 60A, 60B may be higherin height than the portion of the cushioning component 35C having thetubular pillars 44, thus providing greater support and deflectionability at the periphery P.

The bladder element 30 includes a tubular cushioning component 36 thatextends lengthwise along the medial extremity 62 of the sole structure16 generally at the midfoot portion 20 of the sole structure 16. Thecushioning component 36 thus provides cushioning and support for an archarea of the foot 14.

The cushioning component 34A is positioned between the medial extremity62 and the cushioning component 34B. The cushioning component 34B ispositioned between the lateral extremity 60 and the cushioning component34A. The cushioning component 35A is positioned between the medialextremity 62 and the cushioning component 35B. The cushioning component35B is positioned between the lateral extremity 60 and the cushioningcomponent 35A. The cushioning components 34A and 35A are generally on amedial side of a longitudinal midline L of the sole structure 16, andthe cushioning components 34B, 35B are generally on a lateral side ofthe longitudinal midline L. The cushioning components 34A, 34B, 35A, and35B are positioned in the forefoot portion 18 of the sole structure 16.The cushioning component 36 is positioned between the medial extremity62 and the cushioning component 34C. The cushioning component 34C ispositioned between the lateral extremity 60 and the cushioning component36. The cushioning components 34C and 36 are positioned in the midfootportion 20 of the sole structure 16. The cushioning component 35C ispositioned in the heel portion 22 of the sole structure 16.

In the embodiment of FIG. 2, the cushioning component 34A may bereferred to as the first cushioning component, and the cushioningcomponent 35C may be referred to as the second cushioning component.Alternatively, the cushioning component 35A may be referred to as asecond cushioning component, the cushioning component 34B may bereferred to as a third cushioning component, the cushioning component35B may be referred to as the fourth cushioning component, and thecushioning component 34C may be referred to as the fifth cushioningcomponent. Any of the cushioning components 35A, 35B, and 35C may simplybe referred to as the cushioning component, and any of the cushioningcomponents 34A, 34B, and 34C may be referred to as an additionalcushioning component. The cushioning component 34A is rearward of thecushioning component 35A. The cushioning component 34B is rearward ofthe cushioning component 35B. The cushioning component 34C is rearwardof the cushioning component 34B. The cushioning component 35C isrearward of the cushioning component 35B.

The cushioning components 34A, 34B, 34C, 35A, 35B, 35C, and 36 aresubstantially decoupled from one another. As used herein, outer surfacesof adjacent ones of the cushioning components are “substantiallydecoupled” from one another if they are connected with one another onlyby inflation channels or by the tubular cushioning components. In otherwords, adjacent cushioning components may be indirectly connected to oneanother by a channel that establishes fluid communication or by thetubular cushioning components, but the outer surfaces of adjacent onesof the cushioning components are not directly connected to one another,nor are they indirectly connected to one another by webbing formed fromthe material used to form the cushioning components. Adjacent ones ofthe cushioning components 34A, 34B, 34C, 35A, 35B, 35C, and 36 aredisconnected from one another along more than fifty percent of theirperimeters. Moreover, the outer surface of any of the cushioningcomponents 34A, 34B, 34C, 35A, 35B, 35C, and 36 is not connected to theouter surface of an adjacent one of the cushioning components eitherdirectly or by webbing. As discussed herein, adjacent cushioningcomponents are connected only indirectly by channels, such as channels80A, 80B, 80C, 80D, 80E, and 80F. Bladder elements typically havewebbing between inflated portions. Webbing is uninflated portions ofpolymeric material used to form a bladder element, such as sheetmaterial. The bladder element 30 has no such webbing and, instead, gapsare provided between the lengths of each adjacent cushioning component.The arrangement of the cushioning components in the bladder element 30provides cushioning support where needed under the foot 14, while thepolymeric material is absent from other areas in order to minimizematerial waste and enhance flexibility as discussed herein.

The channels 80A, 80B, 80C, 80D, 80E, and 80F connect adjacent ones ofthe cushioning components 34A, 34B, 34C, 35A, 35B, 35C, and 36 alongportions of their perimeters to establish fluid communication betweenthe connected adjacent ones of the cushioning components 34A, 34B, 34C,35A, 35B, 35C, and 36 when the channels 80A, 80B, 80C, 80D, 80E, and 80Fare not sealed. In the embodiment of FIG. 2, the channel 80A connectscushioning component 34A to the cushioning component 35A. The channel80B connects the cushioning component 34B to the cushioning component35B. The channel 80C connects the cushioning component 34C to thecushioning component 34B. The channel 80D connects the cushioningcomponent 34A to the cushioning component 34B. The channel 80E connectsthe cushioning component 34C to the cushioning component 35C. Thechannel 80F connects the cushioning component 36 to the channel 80E,thereby placing the cushioning component 36 in fluid communication withthe cushioning components 34C and 35C. One or more of the channels 80A,80B, 80C, 80D, 80E, and 80F can be sealed so that the adjacentcushioning components connected by the sealed channel are isolated fromfluid communication with one another.

The bladder element 30 includes an inflation port 82 that is disposed ata forward-most periphery 83 of the bladder element 30. Alternatively,the inflation port 82 could be provided at another location along theperiphery of the bladder element 30. In the embodiment shown, theinflation port 82 is connected to the cushioning component 35A and is influid communication with all of the cushioning components 34A, 34B, 34C,35A, 35B, 35C, and 36, via the channels 80A, 80B, 80C, 80D, 80E, and 80Fwhen the channels 80A, 80B, 80C, 80D, 80E, and 80F are not sealed.

The channels 80A, 80B, 80C, 80D, 80E, and 80F and the inflation port 82are formed simultaneously with the cushioning components 34A, 34B, 34C,35A, 35B, 35C, and 36 by thermoforming or blow molding polymericmaterial to form the bladder element 30. Accordingly, the cushioningcomponents 34A, 34B, 34C, 35A, 35B, 35C, 36, the channels 80A, 80B, 80C,80D, 80E, and 80F, and the inflation port 82 are formed simultaneouslywith one another and are of the same material. The inflation port 82 andthe channels 80A, 80B, 80C, 80D, 80E, and 80F are positioned andconfigured to enable the bladder element 30 to be inflated with and toretain different fluid pressures in different portions of the bladderelement 30.

For example, the bladder element 30 may be inflated through theinflation port 82 initially to a first inflation pressure. Next thechannel 80E between the cushioning component 34C and the cushioningcomponent 35C can be sealed (i.e., closed) closed such as by thermalbonding of the walls of the channel 80E together to create a weld 84A.Sealing of the channel 80E is indicated at weld 84A in FIG. 9. Closingthe channel 80E establishes a final first inflation pressure of thecushioning component 35C in the heel portion 22. Inflation fluid in theremainder of the bladder element 30 (i.e., all of the bladder element 30between the inflation port 82 and the closed channel 80E, referred to asthe first remaining unsealed portion) can be released through theinflation port 82, or can remain in the bladder element 30 as inflationcontinues. The first remaining unsealed portion of the bladder element30 is then further inflated through the inflation port 82 to a finalsecond inflation pressure. All portions of the bladder element 30 up tothe weld 84A will thus be at the second inflation pressure. Optionally,the second channel 80F can then be sealed such as by thermal bonding ofthe walls of the channel 80F together to create a weld 84B. Closing thechannel 80F, such as by thermal bonding, establishes the final secondinflation pressure of the cushioning component 36. Inflation fluid inthe remainder of the bladder element 30 between the welds 84A, 84B andthe inflation port 82 (referred to as the second remaining unsealedportion) can be released through the inflation port 82 or can remain inthe bladder element 30 as inflation continues. The second remainingunsealed portion of the bladder element 30 can then be further inflatedthrough the inflation port 82 to a final third inflation pressure. Theinflation port 82 can then be closed, such as by thermal bonding of thewalls of the inflation port 82 to one another. This establishes thethird inflation pressure as the final inflation pressure of thecushioning components 34A, 34B, 34C, 35A, and 35B. Alternatively,additional sequential inflation can occur with any or all of theremaining channels 80A, 80B, 80C and 80D sealed at welds 84C, 84D, 84E,and 84F, respectively, to establish different inflation pressures invarious remaining cushioning components 34A, 34B, 34C, 35A, and 35B. Inyet another alternative, none of the channels 80A, 80B, 80C, 80D, 80E,and 80F are closed depending on the desired final inflation pressuresand desired ability for fluid communication within the bladder element30, or one or more of the channels 80A, 80B, 80C, 80D, 80E, and 80F areclosed but the inflation pressures in the different portions separatedby a closed channel are the same, so that the effect of the closedchannel is only to prevent fluid communication between the portionsseparated by the closed channel.

In an arrangement of the bladder element 30 with the cushioningcomponents 34A, 34B, 34C, 35A, 35B, and 36 as described, various gapsare provided between adjacent ones of the cushioning components 34A,34B, 34C, 35A, 35B, and 36. For example, the cushioning components 34Aand 35A are substantially decoupled from one another, and the cushioningcomponents 34B and 35B are substantially decoupled from one another, sothat a gap G1 extends from the lateral extremity 60 to the medialextremity 62 between the substantially decoupled cushioning components34A and 35A, and between the substantially decoupled cushioningcomponents 34B and 35B. The gap G1 is traversed only by the channels80A, 80B. The channels 80A and 80B are relatively narrow in width incomparison to the cushioning components 34A, 34B, 35A, 35B, and extendgenerally longitudinally between the cushioning components 34A, 34B,35A, and 35B. Accordingly, the channels 80A, 80B do not significantlydiminish flexibility of the sole structure 16 in the fore-aft directionat the gap G1.

Similarly, an additional gap G2 is provided extending from the lateralextremity 60 to the medial extremity 62 between the substantiallydecoupled adjacent cushioning components 36 and 34A, and between thesubstantially decoupled adjacent cushioning components 34C and 34B. Thegap G2 is traversed only by the channel 80C. The channel 80C isrelatively narrow in width in comparison to the cushioning components34A, 34B, 34C, and 36, and extends generally longitudinally between thecushioning components 34B, 34C. Accordingly, the channel 80C does notsignificantly diminish flexibility of the sole structure 16 in thefore-aft direction at the gap G2.

Another gap G3 extends generally in a longitudinal direction between thesubstantially decoupled cushioning components 35A and 35B and continuesbetween the substantially decoupled cushioning components 34A, 34B,interrupted only by the channel 80D. The gap G3 allows increasedflexibility of the sole structure 16 in a lateral direction between thecushioning components 34A, 34B and between the cushioning components35A, 35B. The channel 80D is relatively narrow in width in comparison tothe cushioning components 34A, 34B, 35A, 35B, and therefore does notsignificantly diminish flexibility of the sole structure in the lateraldirection.

Accordingly, the gaps G1 and G2 serve as flexion regions for flexing ofthe sole structure 16 in the fore-aft direction, and gap G3 serves as aflexion region for flexing of the sole structure 16 in a lateraldirection. Any foam 32 that covers the outer surfaces of the cushioningcomponents 34A, 34B, 34C, 35A, 35B, 35C, and 36 and fills the gaps G1,G2, G3 can be configured to have greater flexibility than the inflatedbladder element 30. For example, FIG. 10 shows foam 32 covering outersurfaces 90A, 90B of cushioning components 34B, 35B.

FIG. 11 shows another embodiment of a bladder element 130 that can beused instead of bladder element 30 in the sole structure 16 of FIG. 1.The bladder element 130 has many of the same features as described withrespect to bladder element 30, and such features are referenced with thesame reference numbers as shown and described with respect to FIG. 2.The bladder element 130 includes cushioning components 135A, 135B, and135C used in place of cushioning components 35A, 35B, and 35C,respectively. Each of the cushioning components 135A, 135B, and 135C maybe referred to as a second cushioning component, and has multipleconnecting features 144 positioned inward of an outer periphery of thesecond cushioning component and connecting a first side of thecushioning component to a second side of the cushioning component. Forexample, as shown with respect to the cushioning component 135A in FIG.12. The connecting features 144 are tethers of a tether element 192. Thetether element 192 includes a first plate 194A connected to an innersurface of an upper sheet 170 of the cushioning component 135A and asecond plate 194B connected to an inner surface of a lower sheet 172 ofthe cushioning component 135A. Either adhesive bonding or thermalbonding, for example, may be utilized to secure the first and secondplates 194A, 194B to the upper and lower sheets 170, 172. The tethers144 connect the first plate 194A to the second plate 194B and therebyconnect a first side 150 of the cushioning component 135A to a secondside 152 of the cushioning component 135A. The tether element 192,including the tethers 144 and the plates 194A, 194B, is within afluid-filled cavity 138D of the cushioning component 135A. The interiorcavity 138D is inflated with a fluid that exerts an outward force uponthe sheets 170, 172 and the plates 194A, 194B. The tethers 144 extendacross the interior cavity 138D and are placed in tension by the outwardforce of the pressurized fluid upon the sheets 170, 172, therebypreventing the cushioning component 135A from expanding outward andretaining a desired shape of cushioning component 135A. A peripheralbond joins the polymer sheets 170, 172 to form a seal at a peripheralflange 145A that prevents the fluid from escaping, and the tetherelement 192 prevents the cushioning component 135A from expandingoutward or otherwise distending due to the pressure of the fluid. Thatis, the tether element 192 effectively limits the expansion of interiorcavity 138D to retain an intended shape of surfaces of the cushioningcomponent 135A.

The tethers 144 may be formed from any generally elongate materialexhibiting a length that is substantially greater than a width and athickness. Accordingly, suitable materials for tethers 144 includevarious strands, filaments, fibers, yarns, threads, cables, or ropesthat are formed from rayon, nylon, polyester, polyacrylic, silk, cotton,carbon, glass, aramids (e.g., para-aramid fibers and meta-aramidfibers), ultra-high molecular weight polyethylene, liquid crystalpolymer, copper, aluminum, and steel. Whereas filaments have anindefinite length and may be utilized individually as tethers 144,fibers have a relatively short length and generally go through spinningor twisting processes to produce a strand of suitable length. Anindividual filament utilized in tethers 144 may be formed form a singlematerial (i.e., a monocomponent filament) or from multiple materials(i.e., a bicomponent filament). Similarly, different filaments may beformed from different materials. As an example, yarns utilized astethers 144 may include filaments that are each formed from a commonmaterial, may include filaments that are each formed from two or moredifferent materials, or may include filaments that are each formed fromtwo or more different materials. Similar concepts also apply to threads,cables, or ropes. The thickness of tethers 144 may also varysignificantly to range from 0.03 millimeters to more than 5 millimeters,for example. The tethers 144 may have various shapes in a cross-sectionperpendicular to their length (e.g., a round, a square, a rectangular,an oval, or otherwise closed shape in cross-section). Tethers 144 arearranged in rows that extend longitudinally along the lengths of plates194A and 194B. Only one row is shown in the cross-sectional view of FIG.12.

The cushioning components 135B and 135C are configured in a similarmanner and the tether elements 192 within the cushioning components 135Band 135C are indicated with hidden lines in FIG. 11. The cushioningcomponents 135A, 135B, and 135C are substantially decoupled from thecushioning components 134A, 134B, 134C, and 136, and from one another,in substantially the same manner as discussed with respect to thecushioning components 35A, 35B, and 35C of FIG. 2.

While several modes for carrying out the many aspects of the presentteachings have been described in detail, those familiar with the art towhich these teachings relate will recognize various alternative aspectsfor practicing the present teachings that are within the scope of theappended claims. It is intended that all matter contained in the abovedescription or shown in the accompanying drawings shall be interpretedas illustrative only and not as limiting.

The invention claimed is:
 1. A method of manufacturing a sole structureof an article of footwear comprising: forming a bladder element havingmultiple cushioning components each including a fluid-filled cavity;wherein the bladder element has a first polymeric sheet and a secondpolymeric sheet that together form the cushioning components, and thecushioning components include: a first cushioning component having: asingle central opening extending completely therethrough; and acontinuous fluid-filled cavity surrounding the single central opening;and a second cushioning component having multiple connecting featurespositioned inward of an outer periphery of the second cushioningcomponent, the multiple connecting features connecting a first side ofthe second cushioning component to a second side of the secondcushioning component opposite the first side; wherein the first andsecond cushioning components are spaced apart from one another so thatan outer surface of the first cushioning component is substantiallydecoupled from an outer surface of the second cushioning component;wherein forming the bladder element includes: positioning the first andsecond polymeric sheets in a mold assembly; and thermoforming the firstand second polymeric sheets in the mold assembly to include tubularpillars as the multiple connecting features of the second cushioningcomponent.
 2. The method of claim 1, further comprising: punching holesin the bladder element at the tubular pillars so that the tubularpillars are hollow.
 3. The method of claim 1, further comprising:connecting a tether element to an inner surface of the first polymericsheet and to an inner surface of the second polymeric sheet; wherein thetether element includes the multiple connecting features of the secondcushioning component.
 4. The method of claim 3, wherein connecting thetether element is by adhesive bonding or thermal bonding of the tetherelement to the inner surface of the first polymeric sheet and to theinner surface of the second polymeric sheet.
 5. The method of claim 1,further comprising punching a hole in the bladder element to define thesingle central opening of the first cushioning component.
 6. The methodof claim 1, wherein forming the bladder element includes compressionforming the first and second polymeric sheets to one another at aperipheral flange.
 7. The method of claim 1, wherein forming the bladderelement includes: forming channels connecting adjacent ones of thecushioning components to establish fluid communication between theadjacent ones of the cushioning components.
 8. The method of claim 7,wherein forming the bladder element includes: forming an inflation portdisposed at a periphery of the bladder element and in fluidcommunication with the adjacent ones of the cushioning components viathe channels.
 9. The method of claim 7, further comprising: inflatingthe bladder element to a first inflation pressure; and closing one ofthe channels to form a sealed first portion of the bladder elementhaving the first inflation pressure.
 10. The method of claim 9, furthercomprising: inflating a second portion of the bladder element to asecond inflation pressure different than the first inflation pressure.11. The method of claim 10, wherein the first cushioning component isincluded in the first portion and the second cushioning component isincluded in the second portion.
 12. The method of claim 1, furthercomprising: at least partially covering an outer surface of at least oneof the cushioning components with foam.
 13. The method of claim 12,wherein the single central opening is free of the foam.
 14. The methodof claim 12, further comprising: connecting an outsole or outsoleelements to the foam.
 15. The method of claim 1, further comprising:connecting an outsole or outsole elements to the bladder element.
 16. Amethod of manufacturing a sole structure of an article of footwearcomprising: forming a bladder element having multiple cushioningcomponents each including a fluid-filled cavity; wherein the bladderelement has a first polymeric sheet and a second polymeric sheet thattogether form the cushioning components, and the cushioning componentsinclude: a first cushioning component having: a single central openingextending completely therethrough; and a continuous fluid-filled cavitysurrounding the single central opening; and a second cushioningcomponent having multiple connecting features positioned inward of anouter periphery of the second cushioning component, the multipleconnecting features connecting a first side of the second cushioningcomponent to a second side of the second cushioning component oppositethe first side; wherein the first and second cushioning components arespaced apart from one another so that an outer surface of the firstcushioning component is substantially decoupled from an outer surface ofthe second cushioning component; and wherein the single central openingis free from foam or other structure.
 17. The method of claim 16,wherein forming the bladder element includes: positioning the first andsecond polymeric sheets in a mold assembly; and thermoforming the firstand second polymeric sheets in the mold assembly to include tubularpillars as the multiple connecting features of the second cushioningcomponent.
 18. The method of claim 17, further comprising: punchingholes in the bladder element at the tubular pillars so that the tubularpillars are hollow.
 19. The method of claim 16, further comprisingpunching a hole in the bladder element to define the single centralopening of the first cushioning component.
 20. The method of claim 16,further comprising: connecting a tether element to an inner surface ofthe first polymeric sheets and to an inner surface of the secondpolymeric sheet; wherein the tether element includes the multipleconnecting features of the second cushioning component.